Roofing



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Patented June 9, 1,942

ROCFING John Logan, Jr., Chicago, Ill., assignor` to The Logan-LongCompany, Chicago, Ill., a corporation of Ohio Application April 17,1937, Serial No. 137,507

4 claims.Y (01.11'1-25) My invention relates to roofing, and moreparticularly to an improvement in the type of roofing used to .build upa roof by laying individual' overlapping pieces or shingles, r by1931118 10118 strips running substantially the length of the roof, asdistinguished from roof. coverings built or fabricated in place on thesupporting roof It includes among its objects and advantages an increasein durability under exposure to weather, and a simultaneous increase inthermal insulating value, accompanied by a de:-

crease in cost of manufacture.

In the accompanying drawings:

according to the applicators disclosed in the co- .pending applicationof Meinrad C. Bothe and Frank X. Pfohl, Serial Number 48,800, ledNovember 8, 1935, now Patent No. 2,193,472, granted March l2, 1940.

- Referring rst to the embodiment of Figure 5,

- the strip In receives from the first applicator a mastic massappearing in Figure 2 as Athe layer 88 which, as indicated in Figure 2,may be tapered Figures 1A and 1B are a diagrammatic side elevationindicating the process of manufacture of roofing according-to theinvention;

t;F 'igure 2 is a transverse section of thel finished s rip;

.Figure 3 is a section as on line X--X ofV Fig- `ure 2, diagrammaticallyindicating a product according to the prior art;

Figure 4 is a similar section'indicating a'prod uct according to theinvention;

Figure 5 is a similar section indicating a modifled product accordingt'o the invention;

Figure 6 is a diagrammatic side elevation of an. alternative method forthe use of extremely fine mica flakes; 6 Figure 7 is a section as online 1-1 of Figure Figure 8 is a diagrammatic side elevation of anotherform of equipment for taking eective advantage of the insulatingproperties of the mica with extremely small flakes; and

Figure 9 is a fragmentary section as on line 9 3 of Figure 8.

In the embodiment of the invention selected for illustration, the stripl0 is withdrawn from the roll I2 and passed through asaturating tank Iland a looper I6. It then passes through a first applicator I8, and asecond applicator 20. Thereafter it passes under a hopper 22 where itreceives grits 24 over part or all of its upper' surface.' The roller 28presses the grits into the surface of the strip vand turns the strip thewith a maximum thickness at the middle of the strip, but which extendsthe entire,width of the I strip. This mastic is made up of the usualmatrix of asphaltum to which'has been added, in a uniform andhomogeneous mixture,rilnev flakes of mica 40. The maximum size of theseflakes is the size that will pass through a lforty mesh screen, but, forbest results, L prefer to have the greater proportion of these flakes ofa size to passthrough a sixty mesh screen., After 'reeciving the layer38 in the applicator I8, the strip reg ceives a layer, of asphaltum 'l2over its central portion only, extending from the point 4I to the point46 of Figure 2. And in the applicator 2li it'receives `the relativelythin backing coat 48 of asphaltum.

The thickness of the laye'r l2 is just sumcient to provide an embeddingmatrix for `the grits 24 without having the grits thrust in among themica akes 40.

The subsequent application of grits by the hopper 22 may be only overthe central portion of the strip from point Il to 46 or not. In eitherinstance, substantially the product of Figure 2 will result because thelayer 38 will be so much cooler than the fresh central surface carryingthe layer l2 that the pressure of the roller 28 may be adjusted tosecure retention of grits 24 by the layer 42 but not by the layer 38.

Referring now to Figure 4 I have illustrated a modification in which thelayer 42 has been omitted and the grits are pressed directly into otherside up. A hopper 28 is employed to catch excess grits falling o theroller`26, and-another hopper catches similar grits falling from thesurface of the strip itself. The inverted reach-of the strip receives avery thin coating 32 of fine mica.

through a looper 38 to' any' suitable cuttingV mechanism.

The strip thenpasse's 'over a.l

roll which turns'it'right side up again and i, atively large iiaksindicated in Figure 3, it is" the layer 38. This embodiment, when theperf centage of mica in the layer 38 is low and the mica flakes small,will retain the grits satis.

factorily.

I am aware of prior art shingles in which a large percentage oflargemica flakes are placed in a. layer of asphaltum next the felt baseI9,-and I have shown a diagram of that construction in Figure 3 forpurposes of comparison and explanation. With the-relatively largeamount'of relnecessary to employ a top layer Il of asphaltum withoutmica. of materially greater thickness Y The applicators I8 and `2ll'maybe generally 65 lthan the layer'l! of Figure 5. Thisis'because thrigidity of the mica bearing iayer sz of Figure 3 is so high that anyslight contact between the grits 24 and the layer 52 would create anirregularity that would soon develop a hole under 'exposure totheweather. I also iind that, corri a maximum not exceeding 10%. Thisdecreased percentage of mica leaves the'layer 88 sufilciently plasticand sufficiently bonded to the base I and cover layer 42 to eliminateany-tendency in the shingle to split into laminations. v

With respect to thermal-conductivity, it is noted that at the surface ofcontact between any two dissimilar substances, there is a barrier toheat flow incident tothe physical structure of the contact surface, andthis barrier is in addition to the resistance of each of the substancesthemselves to the transmission of heat. In each of the embodiments ofFigure 3 and Figure 5, we can, therefore, consider a possible path ofheat flow through the asphaltum. 'I'his path will be tortuous because ithas to detour each individual flake of mica, and its total length willbe materially in excess of the thickness of the layer 88 or 52 byapproximately the same amount in both embodiments. Considering the otherpath of heat ow in a geometrically straight line, the path through thelayer 88 will necessarily penetrate a materially smaller thickness ofmica than in the layer 52 because the layer 82 contains a much largerpercentage of mica. But in the layer 88 the direct path may be subjectto two or three times as many surface barriers as in the layer of Figure3. Accordingly, it is evident that a given weight of mica will impose amuch greater obstacle to heat now when it is present in the smallerflakes of Figure 5 than when it is w present in the large flakes ofFigure 3. Accordv line :r- (Figure 2) to make roll roong, or the stripsresulting from such slitting may be cuttransversely to formeitherindividual or strip shingles.

' The foregoing procedure appears to be applicable with mica flakes upto a ilneness of about 80 mesh or 100 mesh. But mica in much finerflakes than these can be used, even down to mica flour. Especially withsuch very fine akes, the procedures of Figures 6 and 8 are advantageousto insure that the bulk of the ilakes will be posi- .tionedsubstantially parallelrto the sheet as a whole, in which position theyconstitute a' more effective thermal insulation barrier than if theywere arranged vat random in the asphaltic mass. Referring first toFigure 6, I have illustrated the same looper i8 as in Figure 1a. Fromthe looper the strip passes under the mixed 5 4 which deposits thepreviously mixed mica and asphalt on the moving'l strip in substantiallythe quantity desired, but only approximately in the desired shape.Thereafter the strip is drawn under a series of combs indicated by thereference character 5l. Each comb comprises a tube '58 through whichsuperheated steam or the products of gaseous combustion maybe passed tokeep the comb at such a temperature that the asphalt will not stick toit. Projecting downwardly and forwardly from the side of each tube isaplurality of teeth having fine needlelike points. Figure 7 indicateshow the points score fine lines in the asphaltic mass as the sheet I8passes under them. Preferably, the point on successive combs arestaggered or offset so that a kneading will take place in the asphalticmass accbrnpaniedy by slight longitudinal displacement that willgenerate suiilcient flow to turn most of the mica akes parallel to thedirection of motion of the strip. In this way, even with extremelyminute flakes, a fair degree of parallel alignment similar to thatillustrated in Figures 4 and 5 can be secured. At 62 I have indicated aprotecting hood over the comb, so that the air space inside the hood maybecome fairly well heated and assist the natural thermal conduction ofheat down the individual comb teeth 60 in keeping the points of theteeth hot enough not to pick up asphalt.

Referring now to Figure 8, the same looper I6 delivers the stripto aseries of applicator units of which three'have been illustrated. Eachapplicator comprises a trough 84 containing asphalt heated considerablyhotter .than its meltingl temperature so that it is freely fluid. Theheated dipping roll 84 is partly immersed in the asphalt andtransfers afilm to the heated transfer roll 66 which transfers a film to the heatedapplicator roll 68. The applicator roll rides directly on the strip i0.The strip lli is preferably pressed lightly against the applicator rollb y a bottom roll 'lll forced up against it by a coil spring 1'2. Iyprefer to drive the applicator roll 68 at a speed approximately10%slower than the speed of the strip I8 so that there will be a slightY wiping or painting action, as the relative cool strip receives fromthe roll most of the of asphalt carried thereby. Each of the asphaltapplicators is preferably housed in a hood "I4 'so that the air aroundthe rolls 84, 8|, and 88 will" not be thick enough to develop any planeof cleavage in the finished product.

and receives alternate thin layers of asphaltum and mica, and the wipingor' painting action ofl each applicator roll 68 forces the additionalasphalt into the mica sufficiently to get a iirm bond with the previouslayer of asphalt. After It will be noted thatthe strip Il carries asubstantially homogeneous mass o1'v asphalt onfits Aupper surface inwhich there are-three layers at 82, 84, and 88 where there is apercentage of mica. At the center oi' each of these layers, the micaconcentration may run as high as 30% without impairing thebond betweenthe different Thus the strip passes under such applicators ousconditions of service.

layers of asphalt, but of course when averaged throughout the entiremass, the percentage will y so fully explain my invention that othersmay, by

applying knowledge current at the time of application, readily adapt thesame for use under vari- It will, for instance. be obvious, that when itis not desired to secure an unusually thin layer of asphalt at eachapplication, in building up the strip as in Figure 9, the asphalt can besimply poured onto the strip in the usual way.

I claim:

1. The method of making roong which comprises: moving a striplongitudinally; superimposing on said strip a mastic material havingiine mica flakes homogeneously mixed therein; combing said masticmaterial with a plurality of rows of heated stationary points into theapproximate cross-sectional configuration of the iinished product; andsmoothing the surface of the combed material info the exactconfiguration o! the finished product.

prises; moving a stripy longitudinally; superimposing on said strip amastic material having .iine mica flakes homogeneously mixed therein;

aligning said flakes approximately with the plane of the stri-p bycombing said mastic material with a plurality of rows 'of heatedstationary points;

and something the surface of the combed material into theexactconilguration of the finished product.

3. The method of making roong which comprises: moving a striplongitudinally; superimposing on said strip a mastic material having -nemica akes mixed therein; combing said mastic material with a pluralityof rows of heated lstationary points; and smoothing the surface of thecom-bed material.

4. Thev method ofV preparing roofing which comprises moving a striplongitudinally; applying a hot lcoating to said strip; permitting saidhot coating to cool at least partially; applying a second hot coatingover a portion only of the area 2. The method oi making roofing which4com-

